Val-Matic 3-Way Tapered Plug Valve

Val-Matic 3-Way Tapered Plug Valve Manual No. CCPV-OM4-1 Operation, Maintenance and Installation Manual INTRODUCTION.2 RECEIVING AND STORAGE 2 VALVE CONSTRUCTION..2 DESCRIPTION OF OPERATION. 3 INSTALLATION 3 VALVE START-UP PROCEDURE 4 TROUBLESHOOTING 4 DISASSEMBLY 4 VALVE DISASSEMBLY..5 RE-ASSEMBLY 7 PARTS AND SERVICE..9 WARRANTY.9 VAL-MATIC VALVE AND MANUFACTURING CORP. 905 Riverside Dr. Elmhurst, IL 60126 Phone (630) 941-7600 Fax (630) 941-8042 www.valmatic.com

VAL-MATIC'S 3-WAY TAPERED PLUG VALVE INTRODUCTION Val-Matic s 3-Way Tapered Plug Valve has been designed to give many years of trouble free operation. This manual will provide you with the information needed to properly install and maintain the valve and to ensure a long service life. All parts are inspected prior to final assembly to insure complete interchangeability of parts. After assembly, each valve receives a hydrostatic shell test, using a pressure equal to twice the valves rated working pressure and a leak test, using a pressure equal to the test pressure for the specified system operation or equal to the CWP for the valve. The standard pressure rating of the 3 through 12 is 150 psi (CWP). An optional 250 psi (CWP) pressure rating is available. Optional Limit Switches may be mounted on the valve to provide local and remote position indication. Improper storage and installation procedures will void warranty. For long term storage greater than six months, the rubber surfaces of the plug should be coated with a thin film of FDA approved grease such as Lubriko #CW-606. Do not expose plug to sunlight or ozone for any extended period. VALVE CONSTRUCTION The 3-Way Tapered Plug Valve consists of a body section having three integrally cast flanges. The top portion of the body has a large integrally cast flanged access port, to which the top access cover is bolted. The size of this access port permits full access to the plug and seat for maintenance or replacement. The flow area through the body inlet, body seat ring and the body outlet is equal to 100% of the nominal inside area of the standard pipe. The valve is capable of handling a wide range of fluids including flows containing suspended solids. The size, flow direction, maximum working pressure, and Model No. are stamped on the nameplate for reference. CAUTION Do not use valve for line testing at pressures higher than nameplate rating or damage to valve may occur. RUBBERED PLUG ACTUATOR MOUNTING BRACKET ACCESS COVER PACKING WITH POP SHIMS BODY The "Maximum Cold Working Pressure" (CWP) is the non-shock pressure rating of the valve at 150 o F. The valve is not intended as an isolation valve for line testing above the valve rating. RECEIVING AND STORAGE Inspect valves upon receipt for damage in shipment. Unload all valves carefully to the ground without dropping. Valves should remain crated, clean and dry until installed to prevent weather related damage. When lifting the valve for installation, make sure that lifting chains, slings or straps are not attached to or allowed to come in contact with the seat areas or actuator handwheel. Do not rest the weight of the valve on the actuator or handwheel. Page 2 of 9 FIGURE 1. 3-WAY PLUG VALVE ADJUSTABLE THRUST BEARING The body has chevron type packing with Val-Matic standard pop shims. The plug and shafts are a single piece construction and is keyed to connect to the actuator. The Buna-N covered plug is fully encapsulated and has three O-ring type sealing beads that provide low pressure sealing when it contacts the body seat. The body seat is fully fusion bonded epoxy (FBE) coated or is optionally available with a welded nickel seating surface. The face to face dimensions of the valve are the same as those of a standard flanged tee for easy installation and interchangeability.

DESCRIPTION OF OPERATION The valve is designed to block flow to one of the three ports or allow flow through all ports. The plug location is shown by the actuator position indication arrow and blocks the port it is pointing toward. The valve is equipped with an adjustable thrust bearing. This adjustment pulls or lifts the tapered plug into intimate contact with the body seating surfaces. It should be adjusted to just seal against the system operating pressure to provide for the longest seal life and additional future adjustment when needed. INSTALLATION The 3-Way Tapered Plug Valve can be used in any orientation relative to vertical. Avoid locating the valve immediately downstream of a pipe elbow or in a cavitation zone because the turbulence in these regions will cause premature wear or damage. Before installing the valve in the space provided, check to make sure that the piping is free of foreign objects such as lumber, tools, rocks, etc., which can damage the 3-Way Plug Valve when it is placed in service. When lifting the valve for installation, make sure that lifting chains or straps are not attached to or allowed to come in contact with the plug face or sealing surfaces. Also do not allow the weight of the valve to rest on the actuator handwheel. Three-Way Plug Valves are furnished with flat faced flanges and should only be mated to a flat faced companion flange. A full faced or ring gasket, that has been lubricated with a gasket joint compound, must be installed between the valve's flange and the companion flange to affect a seal. Flange bolting shall be in accordance with ANSI B16.1 Section 5.2 for cast iron bodies and ANSI B16.42 for ductile iron bodies. Note: Val-Matic does not recommend the use of high strength flange bolting with these valves. Before installing the flange bolting, the valve and the adjacent piping must be supported and aligned to prevent cantilevered stress being transferred to the valve's flanges when installing the flange bolts or studs. Apply a thread lubricant to the flange bolt threads and install the flange bolts and nuts around the flange. Once all the flange bolts or studs are inserted around the flange bolt circle, hand-tighten them. Recommended flange bolt lubricated target torque values for use with resilient gaskets (75 durometer) are given in Table 1. If leakage occurs, allow gaskets to absorb system fluid and check torque and leakage after 24 hours. Do not exceed the bolt rating, the maximum torque of Table 1, compress to more than the gasket manufacturer s thickness recommendation or extrude gasket. TABLE 1. Flange Bolt Target Torque Valve Bolt Target Maximum Size Dia Torque Torque (in) (in) (ft-lbs) (ft-lbs) 2 to 4 5/8 25 90 6-8 3/4 30 150 10-12 7/8 45 205 The target torque for flange bolting is based on the flange construction, system pressure, system temperature, and the gasket material. The valve flange construction is per ASME B16.1 Class 125 (cast iron bodies) or ASME B16.42 Class 150 (ductile iron bodies). The gasket material and design is often the limiting factor for the flange bolt target torque and should best be obtained from the gasket manufacturer. Note: Flange joint leakage can be caused by exceeding the recommended target torque as well as inadequate or non-uniform bolt torque. The flange bolt torque should be applied in several graduated steps using the cross-over bolt tightening method to load the bolts evenly and eliminate concentrated stresses which could fracture or crack the piping or valve's flange. See ASME PCC-1-2010 for details of the cross-over bolt tightening sequence and torque methods. Note that the target torque values provided in ASME PCC-1-2010 are based on the ANSI/ASME steel flange pressure and temperature ratings which exceed those of AWWA and are, therefore, often higher than appropriate for AWWA rated iron valves and flanges. Page 3 of 9

CAUTION The use of ring gaskets or excessive bolt torque may damage valve flanges. VALVE START-UP PROCEDURE When the 3-Way Plug is completely installed, follow the steps outlined below to place valve into service. Once installed, manually operate the valve through all positions of normal operation, check for smooth operation, and pressure test the pipeline. Become familiar with the following adjustments that will affect the closing characteristics of the 3- Way Plug Valve. THRUST BEARING ADJUSTMENT The thrust bearing adjusting screw is covered by a sealed lock cap. After removal of the cap the thrust bearing adjusting screw can be turned to affect the proper seal. Turning the screw to the right pulls the plug farther down into the tapered seat and increases the sealing pressure ability. Turning the screw to the left pushes the plug farther upward away from the tapered seat and decreases the sealing pressure ability. For best long term operation the thrust bearing screw should be adjusted first left (upward) to initiate a small leakage and then back to the right (downward) just until the leakage is stopped. This minimizes seat wear and prolongs the seat life. If after extended service leakage occurs, the thrust bearing can be re-adjusted to eliminate the leakage or the rubbered plug may be replaced. TROUBLESHOOTING Several problems and solutions are presented below to assist you in troubleshooting the valve assembly in an efficient manner. Valve Does Not Open: Check for obstruction in valve or pipeline; see disassembly procedure. DISASSEMBLY The valve can be disassembled without removing it from the pipeline. The valve may also be removed from the pipeline. All work on the valve should be performed by a skilled mechanic with proper tools and a power hoist for larger valves. Disassembly may be required to inspect the disc for wear or the valve for debris or deposits. Refer to Figure 3 and Table 3 for parts identification. Always relieve pressure and drain pipeline before working on the valve. WARNING The pipeline must be relieved of all pressure and drained before removing the actuator, valve, or the valve cover or pressure may be released causing bodily harm. ACTUATOR REMOVAL The valve plug may be positioned to block any port or to leave all ports open by rotating through a 360 arc. The actuator may limit some of these positions based on the application of travel stops in the actuator. The possible configurations are shown in Figure 2 and designations are given in Table 2 below. The actuator should be matchmarked before removal and the actuator configuration designation should be recorded. This configuration should also be indicated on the submittal drawings if available. Leakage at Cover or Flanges: Tighten cover or flange bolts, replace cover seal or flange gasket. Valve Leaks When Closed: Adjust thrust bearing or replace rubbered plug. Inspect rubbered plug for damage or debris. Clean or replace as needed. Inspect body seating surface for damage or debris. Clean, polish, or replace as needed. Page 4 of 9

3. Remove the packing bolts, packing shims, and packing gland follower (9, 29, & 34) on the cover (2). 4. Remove the packing (7) from the cover (2) recess. 5. Remove the cover bolts and washers (4 & 5) on the cover (2). 6. Pry cover (2) loose and lift off valve body. FIGURE 2. 3-WAY PLUG POSITIONS (NOTE: Key in-line with plug face) Table 2. ACTUATOR CONFIGURATION Actuator Plug Positions Plug Configuration Travel 1 2 3 4 Designation 012 90 XX XX 023 90 XX XX 034 90 XX XX 041 90 XX XX 123 180 XX XX XX 234 180 XX XX XX 341 180 XX XX XX 412 180 XX XX XX 1234 360 XX XX XX XX 1. Remove nuts from the studs holding the actuator to the bonnet (11). 7. If desired, remove the upper Grit-Guard seal (10) and shaft bearing (6). 8. Remove the lock cap bolt, washers, lock cap, and lock cap o-ring (24, 25, 21, & 32) from bottom valve trunnion. 9. Remove hex nut (12) from the thrust bearing stud (17). Turn thrust bearing stud (17) counter clockwise as far as possible to raise the plug (3). 10. Remove thrust plate bolts (19) and thrust plate washers (20). If the thrust bearing stud (17) is still engaged with the thrust plate (18) pry and rotate the clockwise to remove. If desired remove the thrust plate o-ring (33). 11. Sling and support rubbered plug (3) and lift out of valve body being careful not to damage scratch, or mar the rubbered face. 12. If desired, remove the shaft cap bolts (16), shaft cap (15), thrust bearing stud (17), and spring washers (31) for the lower plug shaft. 13. If desired, remove the lower Grit-Guard seal (10) and shaft bearing (6). 2. Carefully sling and lift the actuator from the valve s plug shaft (3). 3. Remove actuator key. VALVE DISASSEMBLY 1. Remove the bonnet bolts and washers (13 & 14) on the bonnet (11). 2. Remove bonnet (11). Page 5 of 9

3-WAY PLUG VALVE PARTS CONSTRUCTION 11 2 3429 9 7 1314 8 4 5 1 10 3 6 NOTE: SEE TABLE 3 FOR STANDARD MATERIALS OF CONSTRUCTION OR SUBMITTAL DRAWING FOR SPECIAL CONSTRUCTION 31 16 33 2425 17 32 21 12 10 6 15 22 18 1920 PLUG IN POSITION 1 4 1 3 2 FIGURE 3. VALVE CONSTRUCTION Page 6 of 9

TABLE 3. PARTS AND MATERIALS OF CONSTRUCTION PART NO. PART NAME MATERIAL 1 Body Ductile Iron Fusion Bonded Epoxy Interior/Exterior 2 Cover Ductile Iron Fusion Bonded Epoxy Interior/Exterior 3 Plug Ductile Iron With Buna-N Facing 4 Cover Bolt Steel, Zinc Plated 5 Cover Bolt Washer Steel, Zinc Plated 6 Shaft Bearings Permanently Lubricated Stainless Steel 7 Vee Type Packing Buna-N 8 Cover Seal (O-Ring) Buna-N 9 Packing Gland Follower Cast Iron 10 Grit-Guard Seal Molythane 11 Bonnet Ductile Iron 12 Hex Nut Stainless Steel 13 Bonnet Bolt Steel, Zinc Plated 14 Bonnet Bolt Washer Steel, Zinc Plated 15 Shaft Cap Ductile Iron 16 Shaft Cap Bolt Stainless Steel 17 Thrust Bearing Stud Bronze 18 Thrust Plate Ductile Iron 19 Thrust Plate Bolt Steel, Zinc Plated 20 Thrust Plate Bolt Washer Steel, Zinc Plated 21 Lock Cap Ductile Iron 22 Thrust Stud Washer Stainless Steel 24 Lock Cap Bolt Steel, Zinc Plated 25 Lock Cap Bolt Washer Steel, Zinc Plated 29 Packing Shims Stainless Steel 31 Spring Washer Stainless Steel 32 Lock Cap Seal (O-Ring) Buna-N 33 Thrust Plate Seal (O-Ring) Buna-N 34 Packing Bolt Steel, Zinc Plated = Recommended Spare Part RE-ASSEMBLY All work on the valve should be performed by a skilled mechanic with proper tools and a power hoist for larger valves. Note: All packing, O-rings, Grit-Guard seals, and the rubbered plug face should be coated with FDA approved grease such as Lubriko #CW-606. CAUTION All packing, O-rings, Grit-Guard seals, and the rubbered plug face should be clean and coated with FDA approved grease such as Lubriko #CW-606 at assembly. VALVE RE-ASSEMBLY 1. Install the lower Grit-Guard seal (10) and shaft bearing (6). 2. Install the shaft cap bolts (16), shaft cap (15), thrust bearing stud (17), and spring washers (31) for the lower plug shaft. Note and stack the spring washers in the correct orientation as shown in Figure 4 below. FIGURE 4. SPRING WASHER STACK ORIENTATION Page 7 of 9

3. Sling and support rubbered plug (3) and insert into valve body being careful not to damage scratch, or mar the rubbered face. Guide the lower plug shaft though the lower Grit-Guard seal (10) and shaft bearing (6). 4. Lubricate and install thrust plate o-ring (33) into thrust plate (18) groove. Thread thrust plate (18) counter clockwise onto thrust stud (17). (Note: These are left hand threads.) Install thrust plate bolts (19) and washers (20). Turn thrust stud (17) counter clockwise to lift the plug (3) slightly off the body (1) seats. 5. Place a 0.003 thick shim between plug (3) face and the body (1) seat from the top of the valve. Turn the thrust bearing stud (17) clockwise until the shim is held tightly against the body seat, but do not overtighten. Remove the shim and turn the thrust bearing stud (17) ¼ turn. Install hex nut (12) on the thrust bearing stud (17). Tighten hex nut (12) against the thrust plate (18). This in a jam nut and should be a snug fit without over-tightening. 6. Install the lock cap bolt, washers, lock cap, and lubricated lock cap o-ring (24, 25, 21, & 32) from bottom valve trunnion. 7. Install the lubricated upper Grit-Guard seal (10) and shaft bearing (6) in the cover (2). 8. Install the cover bolts and washers (4 & 5) on the cover (2). The cover bolt torque from Table 4 should be applied in several graduated steps using the cross-over bolt tightening method to load the bolts evenly to eliminate concentrated stresses which could fracture or crack the valve's cover flange. 9. Install bonnet, bonnet bolts and washers (11, 13, & 14). The bonnet bolt torque from Table 5 should be applied in several graduated steps using the cross-over bolt tightening method to load the bolts evenly to eliminate concentrated stresses which could fracture or crack the valve's bonnet flange. Table 5. Bonnet Bolt Torque Valve Bolt Torque Size Size (ft-lbs) 4-6 ½ 75 8-12 / 8 125 10. Install actuator key, actuator studs, actuator, and actuator nuts. The actuator nut torque from Table 6 should be applied in several graduated steps using the cross-over bolt tightening method to load the bolts evenly to eliminate concentrated stresses which could fracture or crack the valve's bonnet flange. Table 6. Actuator Nut Torque Valve Bolt Torque Size Size (ft-lbs) 4 ½ 75 6-8 ¾ 200 10-12 5 / 8 125 11. Pressure test the valve if possible. If necessary, remove the lock cap bolt, washers, lock cap, and lock cap o-ring (24, 25, 21, & 32) from bottom valve trunnion and adjust thrust bearing stud until leak tight. Table 4. Cover Bolt Torque Valve Bolt Torque Size Size (ft-lbs) 4-6 ½ 75 8 5 / 8 125 10-12 ¾ 200 Page 8 of 9

PARTS AND SERVICE Parts and service are available from your local representative or the factory. Make note of the valve Model No. and Working Pressure located on the valve nameplate and contact: Val-Matic Valve and Mfg. Corp. 905 Riverside Drive Elmhurst, IL 60126 Phone: (630) 941-7600 Fax: (630) 941-8042 www.valmatic.com A sales representative will quote prices for parts or arrange for service as needed. LIMITED WARRANTY All products are warranted to be free of defects in material and workmanship for a period of one year from the date of shipment, subject to the limitations below. If the purchaser believes a product is defective, the purchaser shall: (a) Notify the manufacturer, state the alleged defect and request permission to return the product; (b) if permission is given, return the product with transportation prepaid. If the product is accepted for return and found to be defective, the manufacturer will, at his discretion, either repair or replace the product, f.o.b. factory, within 60 days of receipt, or refund the purchase price. Other than to repair, replace or refund as described above, purchaser agrees that manufacturer shall not be liable for any loss, costs, expenses or damages of any kind arising out of the product, its use, installation or replacement, labeling, instructions, information or technical data of any kind, description of product use, sample or model, warnings or lack of any of the foregoing. NO OTHER WARRANTIES, WRITTEN OR ORAL, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY, ARE MADE OR AUTHORIZED. NO AFFIRMATION OF FACT, PROMISE, DESCRIPTION OF PRODUCT OF USE OR SAMPLE OR MODEL SHALL CREATE ANY WARRANTY FROM MANUFACTURER, UNLESS SIGNED BY THE PRESIDENT OF THE MANUFACTURER. These products are not manufactured, sold or intended for personal, family or household purposes. VAL-MATIC VALVE AND MANUFACTURING CORP. 905 Riverside Dr. Elmhurst, IL 60126 Phone (630) 941-7600 Fax (630) 941-8042 www.valmatic.com Page 9 of 9